Radical Organizational Learning, Circadian Rhythms and the Broad Structure Charles M. Weber INFORMS Meeting – San Diego, CA, USA October 11, 2009 10/11/2009 Charles Weber -- INFORMS 2009 1 Abstract • The theory of punctuated equilibrium associates radical change with the disruption of an organization's deep structure. • An empirical study of semiconductor photomask manufacturing • suggests that radical improvement in organizational performance • is contingent upon synchronizing circadian rhythms • across a stable broad structure of organizations • within and outside the firm. 10/11/2009 Charles Weber -- INFORMS Slide 2 Acknowledgements • The research that underlies this paper was funded in part by National Science Foundation Grant #0822062 (Enabling Timely Revolutions in Organizational Performance). 10/11/2009 Charles Weber -- INFORMS Slide 3 Outline of Paper – Timely Revolutions in Organizational Performance – Research Questions • Circadian Rhythms in the Value Network • Pacing Revolutions in Organizational Performance – Empirical Study of Photomask Manufacturing Industry • Research Methods – Preliminary Findings • Leading-edge chipmakers entrain value networks. • “Broad Structure” of revolutions in performance – Implications: Circadian Ecosystems? – Further Research 10/11/2009 Charles Weber -- INFORMS Slide 4 The High Tech Manufacturing Lifecycle • Urgent economic environment (Gersick, 1988) • Product output rate is performance metric (Terwiesch & Bohn, 2001) • Timely revolutions in organizational performance! Performance (Product Output Rate) • • • • Market window open Capacity Constraint (Bohn & Terwiesch, 1999) Time-to-Volume Pressure (Terwiesch & Bohn, 2001) Radical improvement in organizational performance • Market window closed • Negligible output • Market constraint • Output saturation time 10/11/2009 Charles Weber -- INFORMS 2009 Slide 5 Punctuated Equilibrium: The Classical View (Prigogine & Stengers, 1984; Gersick 1991) Performance (Product Output Rate) Revolution • Deep structure becomes unglued • Radical, frame-breaking change (Tushman et al., 1986) Stasis, momentum • Deep structure of subsystems • Incremental change Stasis, momentum • New deep structure • Incremental change time 10/11/2009 Charles Weber -- INFORMS 2009 Slide 6 Radical Learning Without Radical Change! (Weber, 1996-2009) 1.2 Process Quality Learning (CI) Normalized Scale 1 Production Quality Learning (CI) TL(t) / Tmax TL(t/t VP)/TLmax qN(t/t--VPeq. ) (1) q/qVP (1) YL(t) -- eq.)(4a) Y (t/t (4a) YF(t) -- eq.(4c) YF(t/t VP) (4c) YP(t) -- eq. (6) (6) L 0.8 0.6 VP YP(t/tVP) 0.4 Q(t) -- eq. )/Q (7) Q(t/t VP Delayed Impact Production Volume Learning (non-CI) 0.2 tPR/tVP Venture Inception 10/11/2009 0.2 0.4 0.6 PR t /t PD PD VP 0.8 tCS/tVP Product Release 1 CS t /t VP VP Optimal Output Charles Weber -- INFORMS (7) Surge in Organizational Performance 0 0 max 1.2 t/tVP VP • Subsystem Learning! Slide 7 No Strokes of Organizational Genius! (Weber, 1996-2009) • Radical improvement in organizational performance occurs without radical organizational change. – The deep structure stays intact! – Radical change (of leadership, structure, processes and practices) always disables revolutions in organizational performance. • Managers coordinate subsystem-level learning activities to deliver timely revolutions in organizational performance. 10/11/2009 Charles Weber -- INFORMS Slide 8 Research Questions • Are timely revolutions in organizational performance just about subsystem learning? • What about external factors? – Munificence? (e.g., Tushman & Anderson, 1986) – Value networks? (Christensen & Rosenblum, 1995) • How are timely revolutions paced? – Event-based pacing? (Gersick, 1994) – Temporal pacing? (Brown & Eisenhardt, 1997) – Circadian Rhythms? (Ancona and Chong, 1996) 10/11/2009 Charles Weber -- INFORMS 2009 Slide 9 Circadian Rhythms (Ancona & Chong, 1996) • Commonly observed in nature – One component of system sets the pace for the rest of the system. • E.g., the heart sets the pace for the whole human body. – External ‘zeitgebers’ from the environment entrain the human body. • E.g., 24-hour diurnal cycle determines sleep patterns and body temperature. • Circadian rhythms in organizations – Subsystems and organizations are entrained by other subsystems, organizations and the environment. 10/11/2009 Charles Weber -- INFORMS Slide 10 Innovating Like Clockwork: The CMOS Process Technology Supply Chain CMOS Process Supply Chain http://www.itrs.net 2nd Order Suppliers 1st Order Suppliers ChipMakers Lenses, components, materials, software, chemicals are developed on the Moore’s Law schedule. Lithography and process tools, photomasks, wafers, photochemicals are developed on the Moore’s Law schedule. 65 nm 45 nm 32 nm 22 nm 16 nm Comp. μA CMOS process architecture follows Moore’s Law “Sandy Value CY 2005 2006 2009 2010 2011 2012 2013 2014 CoreTM2007 2008 “Nehalem” “Haswell” Bridge” Chain present 10/11/2009 Charles Weber -- INFORMS 2009 Slide 11 Pacing Revolutions in Organizational Performance Performance (Product Output Rate) • Do the circadian rhythms of suppliers determine the timing and durations of timely revolutions by manufacturers? • Do timely revolutions by manufacturers force their tool suppliers to undergo timely revolutions as well? • How about the suppliers of subsystems that go into the tools? Tool Supplier Tool Subsystem Supplier Manufacturer time 10/11/2009 Charles Weber -- INFORMS 2009 Slide 12 Empirical Study of Photomask Manufacturing – Ideal industry to study timing in high tech industries. – Photomasks are within semiconductor value network. • Photomask generations align with semiconductor process generations. – Photomasks contain the patterns that are printed onto microchips. • They must be ready and available before chips are printed. • They are very difficult and expensive to make. – They must be written onto quartz – This requires sophisticated e-beam writing tools and inspection tools. • Tools and quartz plates must be ready for manufacturing before photomasks can be produced in volume. 10/11/2009 Charles Weber -- INFORMS 2009 Slide 13 Research Methods – Initial survey determines needs and practices of photomask manufacturers. (Berglund, Weber, Gabella, 2009) – Case study research (Eisenhardt, 1989; Yin, 1994) • 8 cases; 25 case interviews to date. • Semiconductor process generation constitutes case. – Composite sequence analysis (Miles & Huberman, 1985) • Determines sequence of events that is required to enable timely revolutions in organizational performance – Lots of Secondary sources including … • SIA International Technology Roadmap for Semiconductors • http://en.wikipedia.org/wiki/Intel_Tick-Tock • http://www.intel.com/technology/tick-tock/index.htm 10/11/2009 Charles Weber -- INFORMS Slide 14 Preliminary Findings – Leading-edge chipmakers entrain mask makers (as they do tool makers). • Most leading-edge chipmakers have internal mask shops for leading-edge masks. (Williamson, 1985) – Tool makers and mask makers entrain followers among chipmakers. • Followers among chipmakers do not have internal mask shops have for leading-edge masks. • Mask makers (and tool makers) enable timely revolutions in chipmakers when masks and tools become available – “Broad Structure” in the semiconductor value network • enhances mutual munificence of participants. 10/11/2009 Charles Weber -- INFORMS Slide 15 Pacing in the Photomask Value Network 3 Entrained Timely Revolution Process Research Spike 2.5 Zeitgeber: Leading-edge chipmaker Pilot Development Spike 2 1.5 chips/qtr*(10^-7) 1 masks/qtr*(10^-2) big ticket items/qtr. 0.5 sets of subsys./qtr. 0 0 2 4 6 Time in Years 8 10 • Mask tool subsystems ready for mask tool • Mask tool ready for mask making • Masks ready for chip production 10/11/2009 Charles Weber -- INFORMS Slide 16 The Broad Structure of Photomask Manufacturing Within Same Company Mask Tool orMask Material Tool Maker or Material Mask Tool Maker or Material Mask Tool Maker or Material Maker Mask Shop for Leading-edge Masks Leading -edge Semiconductor Manufacturer Mask Shop for General Purpose Masks Following Semiconductor Manufacturer supplies • • • • • entrains Mask tool makers also make semiconductor tools. The photomask market is not very large (~$3B/year). Mask tool/material makers respond to large, leading-edge chipmakers. Followers are indirectly entrained by leaders. Performance surge delayed -- competitive advantage for leaders. 10/11/2009 Charles Weber -- INFORMS Slide 17 Ticks and Tocks at Intel http://en.wikipedia.org/wiki/Intel_Tick-Tock http://www.intel.com/technology/tick-tock/index.htm Moore’s Law CMOS Process Architecture ? 65 nm Computer MicroArchitecture CY 3D device 45 nm CoreTM 32 nm “Nehalem” 22 nm “Sandy Bridge” 16 nm “Haswell” ? 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 present “old” process; new product Product Shrink Platform Extension Meyer Utterback (1997) ?? Radical Innovation? 10/11/2009 CMOS Architectural Innovation Henderson Clark (1990) Product Platform Renewal Meyer Utterback (1997) Charles Weber -- INFORMS 2009 Slide 18 Circadian Ecosystems Supplier Innovation CMOS Process Architecture 65 nm Computer MicroArchitecture CoreTM Complementor Innovation (Gawer, Cusumano) CY 45 nm 32 nm “Nehalem” 22 nm “Sandy Bridge” 16 nm “Haswell” MS Vista 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 present Moore’s Law • Is Intel the keystone of an ecosystem? (Iansiti, Levien, 2004) • Does Intel’s tick-tock clock set the pace for a significant portion of the global economy? Charles Weber -- INFORMS 10/11/2009 Slide 19 2009 Further Research • Coming up next year: – Qualitative analysis – of sequences of events – that enable timely revolutions – in organizational performance – within the semiconductor value network. • Anticipated Theoretical Contribution – Advance towards a theory of organizational learning for value networks. 10/11/2009 Charles Weber -- INFORMS Slide 20 List of References • • • • • • • • • • Ancona, D., and Chong, C.-L. 1996. Entrainment: Pace cycle, and rhythm in organizational behavior. In B. M. Staw and L. L. Cummings (eds.), Research in Organizational Behavior, 18: 251-284. Greenwich, CT: JAI Press. Berglund, C. N., Weber, C. M., and Gabella, P. 2009. Benchmarking the productivity of photomask manufacturers. IEEE Transactions on Semiconductor Manufacturing (in press). Bohn, R. E. 1995. Noise and Learning in Semiconductor Manufacturing. Management Science 41(1), 31-42. Bohn, R. E., and Terwiesch, C. 1999. The economics of yield-driven processes. Journal of Operations Management 18(1), 41-59. Christensen, C. M. and Rosenbloom, R. S. 1995. Explaining the Attacker’s Advantage: Technological Paradigms, Organizational Dynamics and the Value Network. Research Policy 24, 233-257. Eisenhardt, K. M. 1989. Building theories from case study research. Academy of Management Review 16, 620-627. Gawer, A. and Cusumano, M. 2002. Platform Leadership: How Intel, Microsoft and Cisco drive industry innovation. Harvard Business School Press, Cambridge, MA. Gersick, C. J. G. 1988. Time and transition in work teams: Toward a new model of group development. Academy of Management Journal 31(1), 9-41. Gersick, C. J. G. 1991. Revolutionary Change Theories: A multilevel Exploration of the Punctuated Equilibrium Paradigm. Academy of Management Review 16(1), 10-36. Gersick, C. J. G. 1994. Pacing strategic change: The case of a new venture. Academy of Management Journal 37(1), 9-45. 10/11/2009 Charles Weber -- INFORMS Slide 21 List of References (continued) • • • • • • • • • Henderson, R. and Clark, K. 1990. Architectural Innovation: The Reconfiguration of Existing Product Technologies and the Failure of Established Firms. Administrative Science Quarterly, 35, 9-30. Iansiti, M. and Levien, R. 2004. Strategy as ecology. Harvard Business Review (March), 68-78. Meyer, M. , Tertzakian, P. and Utterback, J. 1997. Metrics for managing research and development in the context of the product family. Management Science 43(1), 88-111. Miles, M. B., and Huberman, A. M. 1984. Qualitative data analysis. Sage, Beverly Hills, CA. Terwiesch, C., and Bohn, R. E. 2001. Learning and process improvement during production ramp-up. International Journal of Production Economics 70(1), 1-19. Tushman, M. and Anderson, P. 1986 . Technological Discontinuities and Organizational Environments. Administrative Science Quarterly, 31, 439-465. Tushman, M. L., Newman, W. H. and Romanelli, E. 1986. Convergence and upheaval: Managing the unsteady pace of organizational evolution. California Management Review 29(1), 29-44. Williamson, O. 1985. The Economic Institutions of Capitalism, New York: Free Press, chapters 2-4, 43-102. Yin, R. K. 1994. Case Study Research, Sage Publishing, Newbury Park, CA. 10/11/2009 Charles Weber -- INFORMS Slide 22